System and method for distillation

ABSTRACT

The system and methods described are directed to a distillation system and method having an evaporator tank with a wall surrounding an interior evaporator tank area. A non-oxidizing gas line is disposed at least partially outside the evaporator tank in communication with the interior evaporator tank area, wherein the non-oxidizing gas line introduces a non-oxidizing gas into the interior evaporator tank; the interior evaporator tank area is generally at or above an ambient atmospheric pressure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 62/146,259 filed Apr. 11, 2015; and U.S. Non-Provisional applicationSer. No. 15/084,443 filed Mar. 29, 2016, which are hereby incorporatedby reference in their entirety.

TECHNICAL FIELD

The embodiments described herein are generally directed to a system andmethod used in a low temperature distillery for the production ofconsumable spirits.

BACKGROUND

Presently, most distilleries use a conventional distillation processthat requires temperature heat inputs (approx. 250° Fahrenheit) anddistillation temperatures from 190° Fahrenheit (F) to 205° F. Thefollowing discussions describe concerns raised by this approach.

Heat input sources: A quality fuel is needed to produce the requiredheat for vaporization of the water into steam. Generally, the source ofthe heat is a fossil fuel burner. This produces carbon dioxideassociated with global warming, and removes a resource fuel that isbetter used elsewhere. In addition, subjecting the beer to these highertemperatures during distillation causes the production of unwantedvolatile organic materials that can have a detrimental effect on thequality of the consumable spirit. In traditional distilleries often theliquor is subjected to multiple distillations and increasingly smallercuts to remove some of these unwanted materials. This is energy wastingand effects product efficiency.

Alternate heat sources: Over thirty percent (30%) of the heat producedin the United States is lost due to the low quality of the heatbyproduct and the lack of technology to take advantage of this verylarge resource. In addition, heat output from solar thermal andgeothermal waste water systems also falls in this range as does the heatrecovered from cogeneration systems. There is plenty of low-grade wasteheat and potential solar or geothermal generated heat in the 120°F.-155° F. ranges.

Oxygen exposure: Oxygen reacts with alcohol and other volatile organicsincluding desired flavor producing compounds to produce an off-tastedistillate. In addition, compounds can be produced that are toxic andproduce hangover symptoms. These reactions are enhanced at the highertemperatures used in traditional distilleries. Minimizing the amount ofoxygen in the distillation environment is therefore desirable for theproduction of a higher quality distillate.

High temperature effects on distilled spirit quality: High temperaturesin the temperature range (190° F.-225° F.) used in traditionaldistilleries has a detrimental effect on distillers beer quality. At thehigher temperatures there is a greater chance of cross reactionsoccurring in the beer especially if oxygen is not minimized. Also, thereare yeast and yeast-by-products that are present in the beer that areheat sensitive. Yeast cells can be destroyed in the (190° F.-225° F.)temperate range, releasing chemicals into the beer. Some of thesematerials produced in the beer at high temperatures can be distilled andcan produce off flavor spirit product and hangover symptoms. It istherefore desirable to distill at lower temperatures where these hightemperature induced changes are minimized.

SUMMARY

In an exemplary embodiment and description, a system and method arepresented that allow production of distillate alcohol at atmosphericpressure, in an environment where oxygen is minimized, at temperaturesin the 120° Fahrenheit (F) to 155° F. range. Such a system reduces someof the variables that produce unwanted compounds that have a detrimentaleffect on the quality of the spirit product during distillation. Inaddition, if the operation is performed in the low-quality heat range(120° F. to 155° F.) there are many waste heat resources or environmentderived heat resources that can be used to power the distillationprocess. Because the distillation is conducted at atmospheric pressureand in a minimized oxygen environment, the process is simple to operateboth manually and automatically, is inexpensive to build (there are manyinexpensive materials that can be used for still construction in thistemperature range) and is safer to operate.

One desirable aspect of the present description is a low temperaturedistillery for the production of quality spirits from variousdistiller's beer sources. The distillate system includes a feed tankcontaining a heat exchanger for producing a heated fermentation product,a pump for pumping the heated distillers beer into spray nozzles in theevaporator tank, a way to recycle un-evaporated distillers beer from theevaporator back into the feed tank where it is reheated and re-injected,a carrier gas (preferably nitrogen) injection system mounted in theevaporator, a blower that recycles the carrier gas and un-condensedvapor through evaporator and the rest of the system, a knockout pot forremoval of entrained liquid from the vapor/carrier gas exiting theevaporator, condenser tank(s) for condensing alcohol containing vaporand a condensate product removal pipe, a pressure regulation system thatwill keep the system at a pressure slightly above atmospheric pressure,a vent for removal of excess carrier gas, a blower for recycle ofcarrier gas and un-condensed vapors and a gate valve to regulate therate of carrier gas/uncondensed vapor recycle.

A second desirable aspect is the use of the above-described system toproduce potable water from ocean water, brackish water, or dirty watersources or the system may be used to clean up industrial waste effluentand to purify chemicals that are volatile including those that aretemperature sensitive or oxygen sensitive (in cases where oxygensensitivity is not present, air can be used directly as the carriergas). Accordingly, the exemplary embodiment and disclosure of the systemand method are intended to provide some of the aspects of the claimedsystem and method, and are not intended to restrict the scope of theclaims herein.

A third desired aspect of the described system is that heat required forthe initial stripping of alcohol from heated beer is usually in the(125° F.-150° F.) range. Recovered waste heat from industrial processesor from environmental inputs can provide this heat thus lowering oreliminating the usual main cost (energy) incurred by a conventionaldistillery. Further rectification of the initial product (50-60%alcohol) from the described system, as is needed in the production ofvodka (law requires distillation to 95% alcohol), can be accomplished atmuch lower overall cost even if the secondary process is conventional.

A fourth desired aspect of the described system is that it significantlyreduces the higher boiling fusel oils due to the low temperature and lowoxygen that the beer is exposed to and the low temperature ofdistillation. Some of these higher boiling fusel oil compounds produceoff taste and have been linked to hangover symptoms. A secondarydistillation (such as needed in vodka production) even if the secondaryprocess is conventional, will not decrease product quality.

A fifth desired aspect of the described system or method is the abilityto utilize solar power, waste heat and other sustainable power sourcesincluding but not limited to wind, geothermal, wave action, geothermal,and the like sources that can be expensed as capital expenses. This is aparadigm shift in energy accounting. This approach allows the volatile,variable cost of energy to be converted into a fixed capitol expense.The majority of the cost of operation is no longer the cost of fuel. Itis now the cost of equipment (solar panels and support systems includingheat exchangers) that is predictable and depreciable.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overhead view of an exemplary embodiment of the claimeddistillery system provided in the present description. FIGS. 2-7 areexplanatory views of each part of the described distillery.

FIG. 2 is an explanatory view of the evaporator part of the distilleryembodied in the present description.

FIG. 3 is an explanatory view of the knockout pot/rectifier in thedistillery embodied in the present description.

FIG. 4 is an explanatory view of the condenser (s) in the distilleryembodied in the present description.

FIG. 5 is an explanatory view of the pressure regulator and vent as wellas the blower and gate valve in the distillery embodied in the presentdescription.

FIG. 6 is an explanatory view of the heated feed tank, which includesthe heat exchanger, the heated recycle pump and the lines leading to thespray heads in the evaporator and the lines returning used feed from theevaporator to the heated feed tank all included in the distilleryembodied in the present description.

FIG. 7 is an explanatory view of the heated liquid tank, whose contentsare pumped through the heated feed tank heat exchanger and also pumpedthrough the solar thermal heaters or other low grade or conventionalheat source (s), which is included in the distillery embodied in thepresent description.

DETAILED DESCRIPTION

The embodiments described herein are not intended to be exhaustive orotherwise limit or restrict the claims to the precise form andconfiguration disclosed in the following detailed description.

The term “beer” and any variation thereof including “distiller's beer”as used throughout the specification is defined hereinafter to mean:fermented pre-distilled product used in the distillation of consumablespirits. Beer is the fermented liquid that is sprayed into theevaporator tank (1) of the distillation system of FIGS. 1-7 and furtherdescribed below.

The term “low temperature” and any variation thereof as used throughoutthe specification is defined hereinafter to include: temperatures in the120° Fahrenheit (F) to 155° F. range and as further described below.

The term “knock-out pot” and any variation thereof as used throughoutthe specification is defined to mean but is not limited to: avapor-carrier gas/liquid separator device used to separate entrained,non-evaporated liquid droplets from the vapor-carrier gas stream and asfurther described and illustrated herein.

The term “rectifier” and any variation thereof as used throughout thespecification is defined to mean but is not limited to: a process thatconcentrates the more volatile species in a volatile gas mix throughcountercurrent liquid/vapor contact. When coolant is passed through theheat exchanger mounted in the knock-out pot, the pot also serves as arectifier in the sense that some condensed vapors from the carrier gasvapor stream coat porous stainless-steel sponge (packing material)wrapped around the heat exchanger. Vapor contact with the liquid coatedsurfaces affects an increase in alcohol content in that vapor.

The term “carrier gas” and any variation thereof as used throughout thespecification is defined to mean but is not limited to: The gasresulting from injecting a non-oxidizing gas into the system to displacea desired portion of the air present. Any non-oxidizing gas iscontemplated including but not limited to nitrogen.

The term “line” and any variation thereof as used throughout thespecification is defined to mean but is not limited to: a structure thatconveys a fluid and/or a gas or functions as a passage. The term lineincludes an aperture between structures.

The term “non-oxidizing gas” and any variation thereof as usedthroughout the specification is defined to include but is not limitedto: an inert gas including but not limited to nitrogen, argon, and thelike, and any variation or combination. The term “non-oxidizing gas”includes a gas used generally to avoid or limit oxidation.

FIGS. 1-7 illustrate an exemplary system of a distillery having anevaporator tank (1) that serves as a vapor generating system when heatedfeed such as beer, as one example discussed here in the exemplarysystem, from the heated feed tank (32) is sprayed into the interior ofevaporator tank (1). The vapors are carried by a circulating carrier gas(a desired amount of non-oxidizing gas is introduced into the system toreduce the amount of air and used to maintain a slight positive pressureduring operation) into a knockout pot (9). Nitrogen is described here asthe main component of the carrier gas but any non-oxidizing gas may beused. Any entrained liquid coming from the evaporator tank (1) isremoved by the knockout pot (9). If a higher alcohol percentagedistillate is desired, the rectifier heat exchange coils (10) of theknockout pot (9) may be activated. The carrier gas/vapor then flows intoone or more chilled condenser tank(s) (16) where the vapor is condensedinto a liquid alcohol distillate product. This distillate product can bewithdrawn from the condenser tank(s) 16 through line 19. The remaininguncondensed vapor/carrier gas mix flows through an exit line (21) intoline (22) to a blower (25) and is recycled into the evaporator tank (1).A hydrostatic pressure regulating system is located in communicationwith the line (22) includes a hydrostatic pressure regulator (23) and avent (24) that allows excess carrier gas/vapor to escape where it can besampled by an oxygen sensor (not shown).

Heating and cooling the carrier gas/vapor during recycle provides themomentum for vapor formation and vapor condensation. As the cool carriergas/vapor and uncondensed vapors entering the evaporator tank (1) comein contact with heated beer that is sprayed into it through a nozzlesystem having spray heads (3 a, 3 b, 3 c), the gasses are heated thusincreasing their ability to carry more vapor. A portion of the injectedheated beer evaporates and the resulting saturated gas mixture (carriergas and vapor) is first treated to remove entrained liquid and thenpassed into the condenser tank(s) (16) where the mix is cooled. The coolcarrier gas has a decreased vapor saturation capacity leading tocondensation of some of the vapor. A larger temperature differentialbetween the heated carrier/vapor entering the condenser (16) and thecooler carrier gas leaving the condenser results in an increase incondensate product. Any vapor not condensed gets recycled with thecarrier gas back into the evaporator (1) for another pass. Carrier gasat different temperatures has different saturation points. The higherthe temperature, the higher the saturation point the more vapor in thecarrier gas. However, saturation can occur at any temperature. Thisembodiment takes advantage of this characteristic and can theoreticallydistill volatile compounds at any temperature as long as the temperaturedifferential between the carrier gas/vapor leaving the evaporator isgreater that the temperature of the carrier gas/vapor leaving thecondenser. With beer solutions (alcohol/water mix) the lowesttemperature range that gives a reasonable distillation rate is generally120° F. for high alcohol beer concentrations (>8%) to 155° F. for lowalcohol beer concentrations (<0.5%).

The desired carrier gas recycle rate controlled by the gate valve (26)in the system varies depending on the temperature range selected. Thisis determined by minimizing the time it takes to distill a given amountof alcohol solution under set temperature conditions. Finally, theminimal introduction of carrier gas into the system should be maintainedduring operation, in order to keep a slight positive pressure in thesystem (0.2-1.0 in of water pressure). As temperature varies, theinternal pressure varies. In operation, a slight positive pressure ofthe very low oxygen containing carrier gas during start up and shut downtimes should be maintained. The level of oxygen in the carrier gas canbe determined using an oxygen probe placed in the carrier gas vent tube(24) coming from the hydrostatic system pressure regulator (23).

All materials that contact beer, alcohol vapor, or distillate in theprovided embodiment of FIGS. 1-7 are made of stainless steel. Pipe ortank connecting fittings are quick-connect fittings. All tanks containmanhole access areas. The system can be easily disassembled and cleaned.The blower and pumps in the system are explosion proof and the system iswell grounded.

During distillation, the quality of the product is often affected by thequality of the water used in the fermentation. The system illustrated inFIGS. 1-7 can also serve as watery. Sea water can be desalinated orstream or brackish waters can be purified using the same distillerysystem described above. The temperature range of operation would have tobe raised to 145° F. to 165° F. in water distillation applications.

Under normal operation, pond water or ocean water at or below 75° F. canbe used as the coolant. In dry areas, evaporative cooling can be used tochill recycled water.

Possible heat sources are many. The operational temperature range islow, allowing the use of waste heat from industrial processes to be usedto power the system. The heat range is excellent for use of recoveredheat from cogeneration operations as well as heat produced by solarthermal or geothermal facilities.

Construction materials are not limited to stainless steel. In otherapplications such as desalination or some industrial applications suchas production of alternative fuels or in the recycle or treatment wasteproducts or in waste reduction applications, it is better to use plasticmaterials that are resistant to corrosive environments and lessexpensive. The low temperature ranges and atmospheric pressureoperational parameters allow different systems to be constructed usingvarious building materials. The least expensive options can be tailoredto the specific conditions that best meet the needs of the process.

Hereinafter, the alcohol water distillery system described in theembodiment of FIGS. 1-7 will be explained with the use of the drawings.In the present embodiment, the distilled alcohol production systemutilizes different source distiller's beers as feed stocks to produceproducts that can be used directly as consumable spirits or can serve asa base for the production of other more complex consumable liquors.

Referring to FIG. 1, a configuration of an exemplary embodiment of adistillery system is shown in the overhead view. In all of thediscussions below, the fermented pre-distilled product used in thedistillation will be referred to as the distiller's beer or just beer. Anon-oxidizing gas such as but not limited to nitrogen is introduced intothe distillation system displacing a desired portion of the air presentin the system. An oxygen probe at vent (24) is used to determine whetherthe air displacement by the non-oxidizing gas is adequate prior to orduring distillation. The distillation system has a hydrostatic pressureregulation device (23) that maintains a slight positive pressure withinthe distillation system.

The gas resulting from injecting non-oxidizing gas into the system todisplace a desired portion of the air present will be referred to as acarrier gas and is cycled and recycled through the distillation systemby a blower (25) mounted in communication with the carrier gas lines(22, 4). Carrier gas flow is regulated by a gate valve (26) mounted incommunication with the carrier gas lines (22, 4). The distiller's beerin the feed tank (32) is heated through an in-tank heat exchanger (30,31) containing heated water cycled from the heated liquid tank (41). Theheat source (48) may be but is not limited to low grade sources such asheat recovered from industrial operations or natural systems such assolar thermal or geothermal operations. This heated beer is then movedby pump (35) under pressure through spray heads (3) mounted in theevaporator tank (1). The spray heads (3) are mounted in such a way toprovide maximum carrier gas exposure in the evaporator tank (1). Thecarrier gas that is circulated through the distillation system by theblower (25) is heated by the heated beer spray from the spray heads (3)causing some of the beer to be evaporated leading to saturation of thecarrier gas with distillers beer vapors. The beer not evaporated flowsfrom the evaporator tank (1) back to the heated feed tank (32) forrecycle. The exit line (7) for carrier gas/vapor in evaporator tank (1)leads to a knockout pot (9). The knockout pot (9) serves two purposes.Porous packing material in the knockout pot (9) removes non-evaporatedliquid entrained in the carrier gas/vapor. In the later stages ofdistillation when alcohol concentration in the beer is low, a heatexchanger (30, 31) mounted in the top of the knockout pot (9) isactivated. Cooling water is introduced into the heat exchanger (30, 31)liquefying small amounts of vapor that coat the packing material. Theinteraction between the rising carrier gas vapor and the fallingcondensed liquid coating the packing material, leads to a higher alcoholpercentage in the vapor stream. This later step is called rectification.Any liquid that is removed during rectification through the liquid drain(13) on the knockout pot (9) is recycled to the heated feed tank (32),complete line not shown. The carrier gas/vapor is then channeled intothe condenser(s) (16) where it comes in contact with an internal coolheat exchanger(s) (17, 18). The temperatures of the circulating gasesare lowered causing condensation of some of the vapor from the carriergas. This condensate(s) (distillate product) is removed from thecondenser(s) (16) through one or more product removal line(s) (19). Thechilled water used in the cool heat exchanger(s) (17, 18) is pumped fromthe cool water source (47). The now cooled dryer carrier gas ischanneled through the line (22) to the blower (25) where it is recycledthrough the system.

The present embodiment for most applications will not needsterilization. In other applications the post distillation equipment mayneed sterilization. In such cases ozone or ultraviolet sterilizationusually be will be adequate. Disinfection of the systems in the presentembodiment could also be achieved using chlorine produced by the onsiteelectrolysis of saltwater. The chlorine will be deactivated by passingthe wash water or gas through an activated carbon filter beforedisposal.

A preferred embodiment is described above. However, it is to beunderstood that various changes can be made with respect to thedescribed embodiment and all such changes as within the true spirit andscope of the claimed invention are intended to be included in theaccompanying claims.

INDUSTRIAL APPLICABILITY

The distillation system, according to the description above has theeffect of being able to distill alcohol, water and other volatilechemical solutions at temperatures significantly lower than the boilingpoint of those solutions. This means that the heat needed to run thesystem can be recovered from waste heat streams, from environmental heatsources or other low-grade heat sources. Because of the low temperatureused, inexpensive materials can be used in the construction of theseunits for certain applications. In addition, a non-oxygen gasenvironment allows oxygen sensitive materials to be distilled. Further,the system can be modified to reduce the volume of waste streams such asfracking fluids, paper production waste and other industrial streams.The use of non-clogging spray heads (3) in the evaporator tank (1) andeasy access to the systems interior, facilitate a wide application forthe described distillation system.

The carrier gas under the above described conditions will becomesaturated with liquid vapor. The higher the temperature, of the drycarrier gas, the higher concentration of vapor that carrier gas cancarry. When an alcohol water mix such as distiller's beer is heated andsprayed into a stream of carrier gas moving through the evaporator tank(1), the carrier gas is heated and becomes saturated with distiller'sbeer vapors. The carrier gas/vapor mix will also entrain small amountsof un-vaporized beer. For this reason, the heated carrier gas/vapor mixis passed through the knockout pot (9) that contains porous packingmaterial. The small droplets of un-vaporized liquid adhere to thepacking material producing a clean carrier gas/vapor stream. Uponentrance into the condenser tank (16), the carrier gas/vapor is cooledwhen it comes in contact with the internal cold-water heat exchangecoils (17, 18). The vapor carrying capacity of the carrier gas decreasesas it is cooled leading to condensation of most of the vapor. The liquidcondensate is removed as spirit distillate and the dryer cool carriergas is channeled through the blower (25) for another pass. Near the endof the distillation process, the percent of alcohol in the distilledliquor may need enhancement. A simple change in the configuration of theknockout pot (9) can convert this system to both a knockout pot and arectifier. A rectifier increases the alcohol concentration in the vaporin the following way. A small cold-water condenser mounted on top of thepacking material in the knockout pot (9) will condense a small portionof the beer vapor in the carrier gas. The condensate produced,containing a higher alcohol concentration than the beer injected intothe evaporator tank (1), coats the packing material. The interaction ofthe incoming vapors with the higher alcohol condensate on the packingmaterial results in a higher alcohol concentration in the carriergas/vapor stream.

Product Made by Process

The above process produces a high-quality consumable spirit product. Dueto the unique distillation conditions (low temperature distillation in alow oxygen environment at atmospheric pressure) the spirit products donot need re-distillation. In addition, the spirit products are smooth totaste and the process eliminates some of the by-products that aresuspected of producing off taste or hangovers. As such, the spiritproducts can be considered quality sipping liquors.

By utilizing different distiller's beer, one can produce primarydistillates that can be consumed directly or used to the produce brandy,vodka, gin, whisky, rum, scotch and other consumable spirits. Because ofthe nature of the distillate, it may not be necessary to age theproducts as long as conventional spirits in order to achieve a smooth,high quality product. The uniqueness of products produced using theabove process description should allow them to be valued as qualityproducts separate from those produced using conventional distillationprocesses.

Optional Systems

The above system for converting the batch distillation process in theembodiment of the present description to: (1) an automated continuousbeer feed process; (2) a temperature controlled companion fuel poweredheat system that operates when the main low temperature heat recoverysystem cannot provide enough heat to the heated liquid tank; (3) a washsystem for automatic cleaning of the areas in the distillation systemthat involve beer contact; and (4) a method for automatic cleaning andsterilization of the distillation system are also contemplated withinthe scope of the description above.

Other Applications

Low temperature distillation in a low oxygen environment at atmosphericpressure in the embodiment described above can be applied to any processthat involves purification of products that have a reasonable vaporpressure at the operational temperature stated above. Distillation ofproducts using this system allows purification to be achieved attemperatures well below the boiling points of those products. Because ofthis, low grade heat resources, normally wasted, can be utilized topower the distillation process. The minimized oxygen and thedistillation at normal pressure are especially attractive in theprocessing of combustible products. The purification of volatilebio-fuels such as methanol, ethanol, other alcohols and certainhydrocarbon products would work well. Certain industrial chemicals couldbe purified including alcohols, aldehydes, ketones, certain acids andhydrocarbon fractions and the like using this approach. Perhaps the mostattractive applications are applying the described process above tolarge scale desalination of sea water and brackish water sources or tothe clean-up and recovery of usable products from industrial wastewaters such as fracking waste, paper waste and other contaminated wastestreams. The most notable attribute of the described process is that itutilizes low grade heat sources such as industrial waste heat,environmental heat resources such as solar thermal and geothermalby-product heat, and recovery heat from combustion sources such asfossil fueled generators and other fueled motor applications to powerthe system. In certain applications, such as the distillation of oxygensensitive materials or the distillation of materials that aretemperature sensitive, this approach could be just as notable.

DRAWING REFERENCES & DESCRIPTION

-   FIG. 2-   evaporator tank-   evaporator tank walls-   3 a side spray head-   3 b top spray head-   3 c opposite side spray head-   4 recycle carrier gas/uncondensed vapor line-   5 used beer return line-   6 non-oxidizing gas injection line, i.e. nitrogen-   7 carrier gas/vapor line leading to the knock-out pot (9)-   FIG. 3-   8 line receiving carrier gas/vapor from evaporator tank-   9 knock-out pot with access tank cover-   10 rectifier heat exchanger coils-   11 stainless steel sponge packing-   12 vapor/gas distribution plate-   13 knock-out pot liquid drain-   14 carrier gas/vapor line leading to the condenser tank(s) (16)-   FIG. 4-   15 line receiving carrier gas/vapor from the knockout pot (9)-   16 condenser tank with access tank cover-   17,18 corrugated stainless steel heat exchanger coils-   19 condensate (distillate) product removal line-   20 carrier gas/vapor distribution plate-   21 carrier gas/vapor exit line-   FIG. 5-   28 line receiving carrier gas and vapor from the condenser tank(s)    (16)-   29 system hydrostatic pressure regulator-   30, 31 excess carrier gas vent port and oxygen test sight-   32 blower to recycle carrier gas and vapor through the system-   33 gate valve to regulate carrier gas/vapor flow-   34 carrier gas/vapor return line to evaporator-   FIG. 6-   28 used beer return from evaporator tank (1) to heated feed tank    (32)-   29 feed tank access cover-   30, 31 corrugated stainless steel heat exchanger coil-   32 heated feed tank-   33 screen for solids retention-   34 spent beer removal line-   35 heated beer pump-   36 a,b,c heated beer feed lines to evaporator (1) spray heads (3    a,b,c)-   FIG. 7-   37 heated water line return from the beer feed tank heat exchanger    (30, 31)-   38 heated water pump—pumps water from heated liquid tank to the feed    tank heat exchanger-   39 valve to regulate heated water flow-   40 beer feed heat exchanger connecting pipe-   41 heated liquid tank—Any heating liquid, including but not limited    to water-   42 heated water return from heat source (48)-   43 pump that pumps water from the heated liquid tank to the heat    source (48)-   44 valve regulates water flow through the heat source (48)-   45 outlet pipe from the heated water pump to the heat source (48)-   46 vent-   47 cool water source for condensers—(FIG. 1)—Any cooling liquid-   48 Heat source—(FIG. 1)

Additional Description

An exemplary distillation system is illustrated in FIGS. 1-7 having anevaporator tank (1) with a wall (2) surrounding an interior evaporatortank area. A non-oxidizing gas line (6) is disposed at least partiallyoutside the evaporator tank (1) in communication with the interiorevaporator tank area, wherein the non-oxidizing gas line (6) introducesa non-oxidizing gas into the interior evaporator tank; the interiorevaporator tank area is generally at or above an ambient atmosphericpressure. A nozzle system (3) is disposed at least partially inside theevaporator tank (1) in communication with a carrier gas. A knock-out pot(9) is disposed in communication with the evaporator tank (1) forreceiving a first product from the evaporator tank (1). A condenser (16)is disposed in communication with the knock-out pot (9) for receiving asecond product. A cool water heat exchanger (17, 18) is disposed atleast partially inside the condenser (16). A recycle line (4, 22) havinga first end and a second end is disposed between the condenser (16) andthe evaporator tank (1) in communication with the condenser (16) and theevaporator tank (1). It is contemplated that one of the possiblenon-oxidizing gases is nitrogen. A rectifier (10) is disposed inside theknockout pot (9); the rectifier (10) is in selectable communication witha cool water source (47). The knock-out pot (9) includes a drain (13) atleast partially disposed outside the knock-out pot (9). The knock-outpot (9) includes a second line (not shown) between the knock-out pot (9)and a heated feed tank (41) in communication with the knock-out pot (9)and the heated feed tank (41). The condenser (16) includes a condensateremoval line (19) disposed at least partially outside the condenser (16)in communication with the condenser (16). A blower (25) is disposedbetween the first end and the second end of the recycle line (4, 22) incommunication with the recycle line (4, 22). A hydrostatic pressureregulation system is disposed between the first end and the second endof the recycle line in communication with the fifth line having a ventin communication with the fifth line (4, 22) for excess carrier gasrelease. A gate valve (26) is disposed between the first end and thesecond end of the recycle line (4, 22) in communication with the recycleline (4, 22) for regulating carrier gas flow rates.

The distillation system of FIGS. 1-7 also shows an evaporator tank (1)having the wall (2) surrounding the interior evaporator tank area. Thenon-oxidizing gas line (6) is disposed at least partially outside theevaporator tank (1) in communication with the interior evaporator tankarea, wherein the non-oxidizing gas line (6) introduces thenon-oxidizing gas into the interior evaporator tank area; the interiorevaporator tank area is generally at or above an ambient atmosphericpressure. The nozzle system having spray heads (3 a, 3 b, 3 c) isdisposed at least partially inside the evaporator tank (1) incommunication with the carrier gas. A second line is disposed betweenthe evaporator tank (1) and the knock-out pot (9) in communication withthe evaporator tank (1) and the knock-out pot (9). A third line isdisposed between the knock-out pot (9) and the condenser (16) incommunication with the knock-out pot (9) and the condenser (16). A coolwater heat exchanger (17, 18) is disposed at least partially inside thecondenser (16). A fifth line having a first end and a second end, thefifth line is disposed between the condenser (16) and the evaporatortank (1) in communication with the condenser (16) and the evaporatortank (1). One of the non-oxidizing gases contemplated is nitrogen. Therectifier (10) is disposed inside the knockout pot (9). The rectifier(10) is in selectable communication with a cool water source (47). Theknock-out pot (9) includes a drain (13) at least partially disposedoutside the knock-out pot (9). The knock-out pot (9) includes a fourthline (not shown) between the knock-out pot (9) and a heated feed tank(32) in communication with the knock-out pot (9) and the heated feedtank (32). The condenser (16) includes a condensate removal line (19)disposed at least partially outside the condenser (16) in communicationwith the condenser (16). A blower (25) is disposed between the first endand the second end of the fifth line in communication with the fifthline. A hydrostatic pressure regulation system (23) is disposed betweenthe first end and the second end of the fifth line in communication withthe fifth line having a vent (24) in communication with the fifth linefor excess carrier gas release. The gate valve (26) is disposed betweenthe first end and the second end of the fifth line in communication withthe fifth line for regulating carrier gas flow rates.

The evaporator tank (1) for distillation includes at least one wall (2)surrounding the interior evaporator tank area. The interior evaporatortank area is generally at or above an ambient atmospheric pressure. Thenon-oxidizing gas line is disposed at least partially outside theevaporator tank wall (2) in communication with the interior evaporatortank area where the non-oxidizing gas line (6) is configured tointroduce the non-oxidizing gas into the interior evaporator tank area.The nozzle system having spray heads (3 a, 3 b, 3 c) is disposed atleast partially inside the evaporator tank (1) configured to be incommunication with the carrier gas. The first exit line (7) is attachedto the wall (2) of the evaporator tank (1) configured to allow agas/vapor to exit the evaporator tank (1). A second exit line (5) isattached to the wall (2) of the evaporator tank (1) configured to allowa used liquid to exit the evaporator tank (1).

A beer cycle method is described having the feed tank (32) incommunication with (a) the evaporator tank (1) and (b) the heated watertank (41), The evaporator tank (1) includes the wall (2) surrounding theinterior evaporator tank area. The nozzle system having spray heads (3a, 3 b, 3 c) is disposed at least partially inside the interiorevaporator tank area. The method includes the steps of: (a) adding abeer product into the feed tank (32); (b) moving a heated water from theheated water tank (41) through a heat exchanger (not shown) disposed atleast partially inside the heated feed tank (32); (c) monitoring thebeer product temperature; (d) pumping the beer product from the feedtank (32) through the nozzle system having spray heads (3 a, 3 b, 3 c)and into the interior evaporator tank area; and (e) returning theun-evaporated beer from the evaporator tank (1) to the heated feed tank(32).

A carrier gas cycle method in a distillation system is described havingthe evaporator tank (1) with the wall (2) surrounding the interiorevaporator tank area. The non-oxidizing gas line (6) is disposed atleast partially outside the evaporator tank (1) in communication withthe interior evaporator tank area; the interior evaporator tank area isgenerally at or above an ambient atmospheric pressure. The nozzle systemhaving spray heads (3 a, 3 b, 3 c) is disposed at least partially insidethe evaporator tank (1). The knock-out pot (9) is in communication withthe evaporator tank (1). The condenser (16) is in communication with theknock-out pot (16). The cool water heat exchanger (17, 18) is disposedat least partially inside the condenser (16). The steps of the carriergas cycle method include: (a) injecting the non-oxidizing gas into theinterior evaporator tank area through the non-oxidizing gas line (6);(b) circulating the carrier gas through the distillation system; (c)monitoring the carrier gas with the oxygen sensor (not shown) incommunication with the distillation system; (d) providing a vent system(24) to allow excess carrier gas buildup to escape; and (e) maintaininga positive pressure in the distillation system. The positive pressure isa pressure above the ambient atmospheric pressure.

A carrier gas saturation method in a distillation system is alsoprovided having the evaporator tank (1) with the walls (2) surroundingthe interior evaporator tank area. The non-oxidizing gas line (6) isdisposed at least partially outside the evaporator tank (1) incommunication with the interior evaporator tank area; the interiorevaporator tank area is generally at or above an ambient atmosphericpressure. The nozzle system having spray heads (3 a, 3 b, 3 c) isdisposed at least partially inside the evaporator tank (1). Theknock-out pot (9) is in communication with the evaporator tank (1). Thecondenser (16) is in communication with the knock-out pot (9). The coolwater heat exchanger (17, 18) is disposed at least partially inside thecondenser (16). The steps of the carrier gas cycle method include: (a)injecting the non-oxidizing gas into the interior evaporator tank areathrough the non-oxidizing gas line (6); (b) saturating the carrier gasby injecting a beer vapor into the interior evaporator tank area makinga saturated carrier gas; (c) removing un-vaporized beer in the knock-outpot (9); (d) cooling the saturated carrier gas in the condenser (16);(e) removing a condensate product from the condenser (16); and (f)recycling the saturated carrier gas into the evaporator (1).

A feed tank method in a distillation system is also provided having theevaporator tank (1) with the walls (2) surrounding the interiorevaporator tank area. The nozzle system having spray heads (3 a, 3 b, 3c) is disposed at least partially inside the evaporator tank (1). Theknock-out pot (9) is in communication with the evaporator tank (1). Thecondenser (16) is in communication with the knock-out pot (9). The coolwater heat exchanger (17, 18) is disposed at least partially inside thecondenser (16). The feed tank (32) with the heat exchanger (not shown)is disposed at least partially within the feed tank (32) incommunication with the nozzle system having spray heads (3 a, 3 b, 3 c).The pump (35) is in communication with the feed tank (32) and theevaporator tank (1). The steps of the feed tank method include: (a)heating a fermented product in the feed tank (32) to between 120° and180° and heating the fermented product to between 120° and 155° reducesthe higher temperature fusel oils, (b) pumping the heated fermentedproduct from the feed tank (32) into the interior evaporator tank areathrough the nozzle system having spray heads (3 a, 3 b, 3 c), (c)removing the un-vaporized liquid in the knock-out pot (9), and (e)condensing an alcohol in the condenser (16). The feed tank methodincludes the pump (35) for (d) pumping the heated fermented product intonozzle system having spray heads (3 a, 3 b, 3 c) in the evaporator tank.The steps include (e) a way to recycle un-evaporated fermented productfrom the evaporator tank (1) back into the feed tank (32) where it isreheated and re-injected. Here, the non-oxidizing gas line (6) isdisposed at least partially outside the evaporator tank (1) incommunication with the interior evaporator tank area. The blower (25)recycles the carrier gas and un-condensed vapor through evaporator tank(1) and the rest of the system. A knockout pot (9) is shown for removalof un-evaporated liquid from the carrier gas exiting the evaporator tank(1) and one or more condenser tanks (16) are provided for condensingalcohol containing carrier gas. The pressure regulation system (notshown) keeps the system at a pressure slightly above atmosphericpressure.

The preceding description has been presented only to illustrate anddescribe exemplary embodiments of the methods and systems of the claims.It is not intended to be exhaustive or to limit the claims to anyprecise form disclosed. It will be understood by those skilled in theart that various changes may be made and equivalents may be substitutedfor elements thereof without departing from the scope of thedescription. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the descriptionwithout departing from the essential scope. Therefore, it is intendedthat the description not be limited to the particular embodimentdisclosed as the best mode contemplated for carrying out thisdescription, but that the description will include all embodimentsfalling within the scope of the claims. The description may be practicedotherwise than is specifically explained and illustrated withoutdeparting from its spirit or scope. The scope of the description islimited solely by the following claims.

What is claimed is:
 1. A beer cycle method having a heated feed tank incommunication with an evaporator tank, the evaporator tank having a wallsurrounding an interior evaporator tank area, a nozzle system beingdisposed at least partially inside the interior evaporator tank area,the method comprising the steps of: (a) placing the evaporator tank areaconfigurable to be operated at or slightly above an ambient atmosphericpressure; (b) adding a beer product into the heated feed tank; (c)pumping the beer product from the heated feed tank through the nozzlesystem and into the interior evaporator tank area, the nozzle systemdisposed at least partially inside the evaporator tank beingconfigurable to be operated in communication with a carrier gas, thenozzle system having a first opening in communication with the heatedfeed tank and configurable to be operated to receive the beer product,the nozzle system having a second opening configurable to be operated tospray the beer product into the evaporator tank to at least partiallyform a vapor-carrier gas, the second opening being configurable to beoperated to spray the beer product below 155 degrees Fahrenheitminimizing yeast cell destruction; and (d) returning the un-evaporatedbeer product from the evaporator tank to the heated feed tank.
 22. Acarrier gas cycle method in a distillation system having an evaporatortank with a wall surrounding an interior evaporator tank area, anon-oxidizing gas line disposed at least partially outside theevaporator tank in communication with the interior evaporator tank area,a nozzle system disposed at least partially inside the evaporator tank,a knock-out pot in communication with the evaporator tank; a condenserin communication with the knock-out pot; a cooling heat exchangerdisposed at least partially inside the condenser, the steps of thecarrier gas cycle method comprising: (a) placing the evaporator tankarea configurable to be operated at or slightly above an ambientatmospheric pressure; (b) injecting a non-oxidizing gas into theinterior evaporator tank area through the non-oxidizing gas line, theinterior evaporator tank area is generally at or above an ambientatmospheric pressure; (c) circulating the carrier gas through thedistillation system; (d) monitoring the carrier gas with an oxygensensor in communication with the distillation system; (e) providing avent system to allow excess carrier gas buildup to escape; (f) pumping abeer product through the nozzle system and into the interior evaporatortank area, the nozzle system disposed at least partially inside theevaporator tank being configurable to be operated in communication witha carrier gas, the nozzle system having a first opening in configurableto be operated to receive the beer product, the nozzle system having asecond opening configurable to be operated to spray the beer productinto the evaporator tank to at least partially form a vapor-carrier gas,the second opening being configurable to be operated to spray the beerproduct below 155 degrees Fahrenheit minimizing yeast cell destruction;and (g) maintaining a slight positive pressure in the distillationsystem.
 23. A carrier gas saturation method in a distillation systemhaving an evaporator tank with a wall surrounding an interior evaporatortank area, a non-oxidizing gas line disposed at least partially outsidethe evaporator tank in communication with the interior evaporator tankarea, a nozzle system disposed at least partially inside the evaporatortank, a knock-out pot in communication with the evaporator tank; acondenser in communication with the knock-out pot; a cooling heatexchanger disposed at least partially inside the condenser, the steps ofthe carrier gas cycle method comprising: (a) placing the evaporator tankarea configurable to be operated at or slightly above an ambientatmospheric pressure; (b) injecting a non-oxidizing carrier gas into theinterior evaporator tank area through the non-oxidizing gas line; (c)saturating the non-oxidizing carrier gas by pumping a beer productthrough the nozzle system and into the interior evaporator tank area,the nozzle system being configurable to be operated in communicationwith the non-oxidizing carrier gas, the nozzle system having a firstopening in configurable to be operated to receive the beer product, thenozzle system having a second opening configurable to be operated tospray the beer product into the evaporator tank to at least partiallyform a vapor-carrier gas, the second opening being configurable to beoperated to spray the beer product below 155 degrees Fahrenheitminimizing yeast cell destruction; (c) removing an un-vaporized beerproduct in the knock-out pot; (d) cooling the saturated non-oxidizingcarrier gas in the condenser; (e) removing a condensate product from thecondenser; and (f) recycling the saturated non-oxidizing carrier gasinto the evaporator.